Intermittently coated dry electrode for energy storage device and method of manufacturing the same

ABSTRACT

Methods for manufacturing intermittently coated dry electrodes for energy storage devices and energy storage devices including the intermittently coated dry electrodes are disclosed. In one embodiment, the method includes providing a metal layer and providing an electrochemically active free-standing film formed of a dry active material. The method also includes combining the electrochemically active free-standing film and the metal layer to form a combined layer. The method further includes removing a portion of the electrochemically active free-standing film from the combined layer so that the electrochemically active free-standing film is intermittently formed on the metal layer in a longitudinal direction of the metal layer.

RELATED APPLICATIONS

This application claims priority to and the benefit of ProvisionalApplication No. 62/757,609 filed on Nov. 8, 2018 in the U.S Patent andTrademark Office, the entire contents of which are incorporated hereinby reference.

BACKGROUND Field

The described technology generally relates to energy storage devices,and specifically to methods for manufacturing intermittently coated dryelectrodes for energy storage devices and energy storage devicesincluding the intermittently coated dry electrodes.

Description of the Related Technology

Electrical energy storage cells are widely used to provide power toelectronic, electromechanical, electrochemical, and other usefuldevices, for example, hybrid vehicles, plug-in hybrid vehicles and pureelectric vehicles. Such cells include batteries such as primary chemicalcells and secondary (rechargeable) cells, fuel cells, and variousspecies of capacitors, including ultracapacitors. Increasing theoperating power and energy of energy storage devices, includingcapacitors and batteries, would be desirable for enhancing energystorage, increasing power capability, and broadening real-world usecases.

SUMMARY

For purposes of summarizing the described technology, certain objectsand advantages of the described technology are described herein. Not allsuch objects or advantages may be achieved in any particular embodimentof the described technology. Thus, for example, those skilled in the artwill recognize that the described technology may be embodied or carriedout in a manner that achieves or optimizes one advantage or group ofadvantages as taught herein without necessarily achieving other objectsor advantages as may be taught or suggested herein.

One inventive aspect is an intermittently coated dry electrode for anenergy storage device.

Another aspect is a method of manufacturing an intermittently coated dryelectrode for an energy storage device.

Another aspect is an energy storage device including intermittentlycoated dry electrodes.

Another aspect is a method of manufacturing a dry electrode for anenergy storage device, comprising: providing a metal layer; providing anelectrochemically active free-standing film formed of a dry activematerial; combining the electrochemically active free-standing film andthe metal layer to form a combined layer; and removing a portion of theelectrochemically active free-standing film from the combined layer sothat the electrochemically active free-standing film is intermittentlyformed on the metal layer in a longitudinal direction of the metallayer.

Another aspect is a dry electrode for an energy storage device,comprising: a metal layer; and an electrochemically active free-standingfilm formed of a dry active material, wherein the electrochemicallyactive free-standing film comprises a plurality of film portionsintermittently formed on the metal layer in a longitudinal direction ofthe metal layer to expose a portion of the metal layer.

Another aspect is an energy storage device, comprising: a firstelectrode; a second electrode; and a separator interposed between thefirst and second electrodes, wherein each of the first and secondelectrodes comprises; a metal layer; and an electrochemically activefree-standing film formed of a dry active material, wherein theelectrochemically active free-standing film comprises a plurality offilm portions intermittently formed on the metal layer in a longitudinaldirection of the metal layer to expose a portion of the metal layer.

Another aspect is a method of manufacturing a dry electrode for anenergy storage device, comprising: providing a metal layer; providing afirst electrochemically active free-standing film formed of a dry activematerial; providing a second electrochemically active free-standing filmformed of a dry active material; combining the first and secondelectrochemically active free-standing films with the metal layer toform a combined layer such that the metal layer is interposed betweenthe first and second electrochemically active free-standing films; andremoving a first portion of the first electrochemically activefree-standing film and a second portion of the second electrochemicallyactive free-standing film from the combined layer so that each of thefirst and second electrochemically active free-standing films isintermittently formed on the metal layer in a longitudinal direction ofthe metal layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating a process for manufacturing a dryelectrode for an energy storage device.

FIG. 2 illustrates an electrochemically active free-standing film placedover a continuously adhesive coated metal foil before heat and/pressureis applied thereto.

FIG. 3 illustrates the electrochemically active free-standing filmlaminated onto the continuously adhesive coated metal foil after heatand pressure is applied thereto.

FIG. 4 illustrates an example continuously coated dry electrode.

FIG. 5 illustrates an electrochemically active free-standing film placedover an intermittently adhesive coated metal foil before heat andpressure is applied thereto.

FIG. 6 illustrates the electrochemically active free-standing filmlaminated onto the intermittently adhesive coated metal foil after heatand pressure is applied thereto.

FIG. 7 illustrates an example intermittently coated dry electrodeaccording to an embodiment.

FIG. 8 illustrates an electrochemically active free-active filmaccording to an embodiment.

FIG. 9 illustrates an example metal foil that includes metal foilportions that are intermittently coated with adhesive and uncoated metalfoil portions according to an embodiment.

FIG. 10 illustrates an intermittently coated dry electrode according toanother embodiment.

FIG. 11 illustrates an electrochemically active free-active film placedover an example uncoated metal foil according to another embodiment.

FIG. 12 illustrates a laminator roll assembly according to an embodimentthat produces intermittently coated electrode laminates.

FIG. 13 illustrates an intermittently coated dry electrode produced bythe laminator roll assembly of FIG. 12, according to an embodiment.

FIG. 14 illustrates an electrochemically active free-active film placedover an example uncoated metal foil according to another embodiment.

FIG. 15 illustrates a laminator roll assembly according to anotherembodiment.

FIG. 16 illustrates an intermittently coated dry electrode produced bythe laminator roll assembly of FIG. 15, according to another embodiment.

FIG. 17 illustrates a laminator roll assembly that produces anasymmetric intermittent double-side coated dry laminate shown in FIG. 18according to an embodiment.

FIG. 18 illustrates a cross-sectional view of the asymmetricintermittent double-side coated dry laminate produced by the laminatorroll assembly shown in FIG. 17 according to an embodiment.

FIG. 19 illustrates a laminator roll assembly that produces anasymmetric intermittent double-side coated dry laminate shown in FIG. 20according to another embodiment.

FIG. 20 illustrates a cross-sectional view of the asymmetricintermittent double-side coated dry laminate produced by the laminatorroll assembly shown in FIG. 19 according to another embodiment.

FIG. 21 illustrates an intermittently coated dry electrode to beconnected to an electrode tab according to an embodiment.

FIG. 22 illustrates an energy storage device according to an embodiment.

FIG. 23 illustrates a method of manufacturing a dry electrode for anenergy storage device according to an embodiment.

FIG. 24 illustrates a method of manufacturing a dry electrode for anenergy storage device according to another embodiment.

DETAILED DESCRIPTION

Provided herein are various embodiments of a dry electrode for use inenergy storage devices. In particular, in certain embodiments, energystorage devices disclosed herein include an intermittently coated dryelectrode. For example, the described technology can provide dryelectrode coating capability to include intermittent patterns for use incylindrically wound cells with current collection designed across thewidth of the electrode. Also provided are methods for manufacturing suchintermittently coated dry electrodes. The disclosed embodiments canprovide a simplified and cost-effective electrode coating procedure forenergy storage devices.

Energy storage devices such as lithium ion batteries have been relied onas a power source in numerous commercial and industrial uses, forexample, in consumer devices, productivity devices, and in batterypowered vehicles. However, demands placed on energy storage devices arecontinuously—and rapidly—growing. For example, the automotive industryis developing vehicles that rely on compact and efficient energystorage, such as plug-in hybrid vehicles and pure electric vehicles.Lithium ion batteries are well suited to meet future demands.

Key components of the storage potential of an energy storage device areelectrodes. The electrochemical capabilities of electrodes, for example,the capacity and efficiency of battery electrodes, are governed byvarious factors. For example, distribution of active material, binderand additive(s); the physical properties of materials therein, such asparticle size and surface area of active material; the surfaceproperties of the active materials; and the physical characteristics ofthe electrode film, such as density, porosity, cohesiveness, andadhesiveness to a conductive element. Dry processing methodstraditionally used a high shear and/or high pressure processing step tobreak up and commingle electrode film materials, which may contribute tostructural advantages over electrode films produced using a wet process.

FIG. 1 is a block diagram illustrating a process 10 for making a dryelectrode for an energy storage device. As used herein, the term “dry”implies non-use of liquid-phase solvents and additives in mixing andcoating process of electrode during process steps described herein,other than during a final impregnating electrolyte step. The process 10shown in FIG. 1 begins by dry blending 18 dry active material particles12, dry conductive particles 14 and dry binder particles 16 to form adry mixture. Furthermore, dry conductive particles 21 and dry binderparticles 23 are also dry blended 19 to form a dry mixture which can beprovided to an optional dry fibrillizing step 26 or 29. The dry mixtureis fibrillized in a dry fibrillizing step 20 using, for example, ajet-mill (not shown). During the dry fibrillizing step 20, high shearforces are applied to the dry mixture in order to physically stretch itand form a network of thin web-like fibers. In a dry feed step 22 or 29,the respective separate mixtures of dry particles formed in steps 19 and20 are provided to respective containers (not shown) to form a dry film.The dry film is subsequently dry compacted and calendared by a roll-millor calendar 24 to provide an embedded/intermixed dry film or aself-supporting electrode film (or electrochemically activefree-standing film). The embedded/intermixed dry film is attached orbonded to a current collector (e.g., metal foil) 28. A more detailedprocess of making an embedded/intermixed dry film including types ofmaterials forming the dry films and materials forming the currentcollector is disclosed in U.S. Pat. No. 7,352,558, which is incorporatedby reference herein in its entirety.

A self-supporting dry electrode film manufactured above may provideimproved characteristics relative to a typical electrode film that ismanufactured using a wet process. For example, a dry electrode film asprovided herein may provide one or more of improved film strength,improved cohesiveness, improved adhesiveness, improved electricalperformance, or reduced incidence of defects. The defects may includeholes, cracks, surface pits in the electrode film. The adhesiveness maybe adhesiveness to a current collector. The electrical performance maybe specific capacity. The film strength may be tensile strength.

The materials and methods provided herein can be implemented in variousenergy storage devices. As provided herein, an energy storage device canbe a capacitor, a lithium ion capacitor (LIC), an ultracapacitor, abattery such as a lithium ion battery, or a hybrid energy storage devicecombining aspects of two or more of the foregoing.

FIGS. 2-4 illustrate a process of making an example dry electrode. Theexample dry electrode may be an anode or a cathode. Referring to FIG. 2,an electrochemically active free-standing film 34 is placed over a metalfoil 30. The electrochemically active free-standing film 34 may beformed of an electrochemically active material. The electrochemicallyactive material can be an anode active material or a cathode activematerial. The anode active material may include, for example, graphite,silicon, tin, lithium titanate, lithium metal, lithium alloy compound orcomposites derived from these compositions. The cathode active materialmay include, for example, nickel manganese cobalt oxide (NMC), nickelcobalt aluminum oxide (NCA), lithium cobalt oxide (LCO), lithium ironphosphate (LFP), activated carbon, lithium manganese oxide (LMO),lithium nickel manganese oxide (LNMO), iron sulfide, sulfur orcomposites derived from these compositions. The metal foil 30 may beformed of, for example, copper, aluminum, titanium, stainless steel or acombination thereof. The description of this paragraph applies to theremaining embodiments.

The metal foil 30 includes a continuously adhesive coated metal foilportion 32 and an uncoated metal foil portion 36. The continuouslyadhesive coated metal foil portion 32 is continuously coated with anadhesive in a longitudinal direction of the metal foil 30. Theelectrochemically active free-standing film 34 may be placed over amajority of the adhesive coated metal foil portion 32. The activefree-standing film 34 may also be placed over a portion of the uncoatedmetal foil portion 36 as shown in FIG. 2. In some embodiments, theactive free-standing film 34 may not be placed over any portion of theuncoated metal foil 36 (not shown). After heat and/or pressure isapplied to the active free-standing film 34 and the adhesive coatedmetal foil portion 32, the active free-standing film 34 is laminatedonto the adhesive coated metal foil portion 32 (FIG. 3). The laminatedfilm of FIG. 3 includes an area of an unattached electrochemicallyactive free-standing film 42 and an area of a film laminated to a coatedmetal foil 44. The portion of the adhesive coated metal foil 32 that isnot directly attached to the active free-standing film 34 may be removedby, for example, peeling or slitting. A continuously adhesive coated dryelectrode 46 is subsequently formed (FIG. 4). The dry electrode 46 ofFIG. 4 includes an uncoated metal foil portion 48 that can be used forelectrically connecting the dry electrode 46 to other electricalcomponents such as an electrode tab, positioned inside the finalelectrical device. The size or dimension of the uncoated foil portion 48generally constitutes a significant portion of the final dry electrode46. Thus, the dimension of the continuously adhesive coated dryelectrode 46 can be limited by the dimension of the uncoated portion 48.

FIGS. 5-7 illustrate a process of making an example intermittinglycoated dry electrode according to an embodiment. Referring to FIG. 5, anelectrochemically active free-standing film 56 is placed over a metalfoil 58. The metal coil 58 is discontinuously or intermittently coatedwith an adhesive or an adhesive layer (not shown) in a longitudinaldirection thereof. The adhesive layer may be formed from one or more ofglue or thermoplastic such as polyethylene (PE), polyvinyl chloride(PVC), polystyrene (PS), acrylics, fluoropolymers, polyesters,polyimides, polyamides, polyurethanes, polycarbonates, carbon or acombination thereof. The adhesive layer may be conductive (e.g., carbonadhesive layer). The coating weight for the conductive adhesive layermay be in the range of about 1 gram per square meter per side to about 5grams per square meter per side with a dry coating density of about 0.2grams per square centimeter per side to about 1.1 grams per squarecentimeter per side. The above coating weight and density can provide anoptimum balance between a mechanically robust attachment offree-standing active films and lower costs. For example, the conductiveadhesive layer can be thin (lowest loading weight) and as low in densityas possible (minimal carbon adhesive material usage). These weight anddensity numbers are merely examples and other weight and density valuesare also possible. This applies to the remaining embodiments. The metalcoil 58 includes coated portions 52 (or intermittently adhesive coatedmetal foil portions) and an uncoated portion 54 (or uncoated metal foilportion). The uncoated portion 54 is interposed between the adhesivecoated portions 52. The uncoated portion 54 may be placed around themiddle of the metal foil 58 in the longitudinal direction of the metalfoil 58, however, the position of the uncoated portion 54 is not limitedthereto. The discontinuously coated metal foil 58 may be produced via,for example, as gravure roll coating or slot die coating or screenprinting or laser jet printing.

After heat and/or pressure is applied to the stacked layers (58, 56),the active free-standing film 56 is laminated onto the adhesive coatedmetal foil portions 52 (FIG. 6). The laminated film of FIG. 6 includesan area of an unattached electrochemically active free-standing film 62and an area of a film laminated onto a coated metal foil 64. The area ofthe unattached electrochemically active free-standing film 62 includesan upper portion and a middle portion (see two arrows shown in the upperregion of FIG. 6) of the active free-standing film 56 as shown in FIG.6. The area of the film laminated to the coated metal foil 64 includesleft and right portions (see two arrows shown in the lower region ofFIG. 6) of the active free-standing film 56 that vertically overlap theadhesive coated metal foil portions 52.

After the portion of the active free-standing film 56 that verticallyoverlaps the uncoated metal foil portion 54 is removed, adiscontinuously or intermittently coated dry electrode 72 is formed(FIG. 7). The peeling/trimming or removal of the overlapping portion ofthe unattached free-standing film 62 can be carried out using, forexample, an air knife and/or vacuum. Since the uncoated metal foilportion 54 is not coated with an adhesive and thus is not adhered to thecorresponding portion of the active free-standing film 56, theoverlapping free-standing film portion can be more easily removedcompared to the continuously adhesive coated electrode shown in FIGS.2-4. The dry electrode 72 includes two active free-standing filmportions 64 a and 64 b that are discontinuously or intermittently formedwith respect to each other. The dry electrode 72 includes an uncoatedfoil portion 54 that is used for electrically connecting the electrode72 to other elements such as an electrode tab. The dimension of theuncoated portion 54 may be substantially smaller than the uncoatedportion 48 of the continuously coated dry electrode 46 in FIG. 4. Forexample, the width of the uncoated foil portion 54 may be 1, 2, 3, 4, 5,6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 millimeters, orany width in a range between any two of these values. In otherembodiments, the width of the uncoated foil portion 54 may be 5-10,10-20, 20-30, 30-40, or 40-50 millimeters or more in width. Thus, theembodiment shown in FIGS. 5-7 can provide a simplified andcost-effective dry electrode making procedure for energy storagedevices.

FIGS. 8-10 illustrate a process of making an example dry electrodeaccording to another embodiment. In FIG. 8, an electrochemically activefree-standing film 80 is shown. The active free-standing film 80 may belonger than the active free-standing film 34 shown in FIG. 2 and theactive free-standing film 56 shown in FIG. 5. FIG. 9 shows a metal foil90. The metal foil 90 is discontinuously or intermittently coated withan adhesive in a longitudinal direction thereof as shown in FIG. 9. Theactive free-standing film 80 may be similar in dimension to the metalfoil 90. The metal coil 90 includes coated portions 92 (orintermittently adhesive coated metal foil portions) and uncoatedportions 94 (or uncoated metal foil portions). The coated portions 92and the uncoated portions 94 are alternately formed with respect to eachother as shown in FIG. 9. The discontinuously coated metal foil portions92 may be formed by intermittently coating an adhesive (described above)on the metal foil 90 via, for example, gravure roll coating, slot diecoating, screen printing or laser jet printing.

In FIGS. 9 and 10, x represents the width of each of the uncoated metalfoil portions 94 measured in the longitudinal direction of the metalfoil 90, and y represents the width of each of the coated metal foilportions 92/102 measured in the longitudinal direction. Although onlythree sets of the coated portions 92 and the uncoated portions 94 areshown in FIG. 9, more pairs of coated portions and uncoated portions canbe formed (not shown). Those more pairs can be alternately formed withrespect to each other. It should be realized that the ration of x/y maybe any value where y is typically greater than x such that the width ofthe coated portion is greater than the value of the uncoated portion. Inone embodiment, as discussed more fully below, the width y relates tothe circumference of the final electrode winding such that each uncoatedsection 94 aligns with each other when the laminate film is wound into arolled electrode format.

Similarly to FIGS. 5 and 6, after the active free-standing film 80 isplaced over the intermittently adhesive coated metal foil portions 92and the uncoated metal foil portions 94 of the metal foil 90, heatand/or pressure may be applied to the stacked layers (80, 90) so thatthe active free-standing film 80 is laminated onto the adhesive coatedmetal foil portions 92. Again, the active free-standing film 80 may notbe adhered or very weakly attached to the uncoated metal foil portions94 on which no adhesive is formed. Since there are three uncoated metalfoil portions 94 provided in FIG. 9, the laminated film 100 in FIG. 10would initially include three portions (not shown) of the activefree-standing film 80 that respectively vertically overlap the threeuncoated metal foil portions 94 (before the three portions are removed).After the overlapping portions of the active free-standing film 80 areremoved, a discontinuously or intermittently coated dry electrode 100 isformed (FIG. 10). The peeling or removal of the overlapping portions ofthe active free-standing film 80 can be done in the same way discussedabove with respect to the embodiments of FIGS. 5-7.

The electrode 100 includes intermittently coated portions 102 anduncoated foil portions 94. At least one of the uncoated foil portions 94can be used for electrically connecting the electrode 100 to otherelements such as an electrode tab. The dimension of each of the uncoatedportions 94 may be substantially smaller than the uncoated portion 48 ofthe continuously coated dry electrode 46 in FIG. 4. Thus, the embodimentshown in FIGS. 8-10 can also provide a simplified and cost-effective dryelectrode making procedure for energy storage devices.

FIGS. 11-13 illustrate a process of making an example dry electrodeaccording to another embodiment. In FIG. 11, an electrochemically activefree-standing film 110 and a metal foil 120 uncoated with an adhesiveare shown. The active free-standing film 110 may have the same dimensionas that of the active free-standing film 80 shown in FIG. 8. The activefree-standing film 110 is placed over and aligned with the uncoatedmetal foil 120 before a laminator roll procedure in FIG. 12 isperformed. For the purpose of illustrating both the active free-standingfilm 110 and the uncoated metal foil 120, FIG. 11 shows that the twoelements 110 and 120 are slightly misaligned with each other, however,the elements 110 and 120 would be aligned before the laminator rollprocedure.

Referring to FIG. 12, the active free-standing film 110 and the uncoatedmetal foil 120 are inserted into and laminated by a laminator rollassembly 130. The laminator roll assembly 130 includes a pair of rollers132 and 134. The rollers 132 and 134 may have substantially the samediameter. The rollers 132 and 134 may be formed of the same material ordifferent materials having the same or similar level of hardness so thata substantially uniform pressure is applied to the stacked layers (110,120) by both of the rollers 132 and 134. The rollers 132 and 134respectively have openings 136 and 138. The openings 136 and 138 mayhave the same dimension. In one embodiment, the openings 136 and 138 mayhave the same width or circumferential length (x) and same depths. Inanother embodiment, the openings 136 and 138 may have the same width(x), but may have different depths. Each of the openings 136 and 138 hasa width (x) which is the same as that of each of uncoated metal foilportions 144 shown in FIG. 13. The length (y) of the remaining portionof each of the rollers 132 and 134 is the same as the width of each ofintermittently coated portions 142 shown in FIG. 13.

A skilled person would appreciate that each of the laminate rollers 132and 134 may have different dimensions of x and y, depending on therequired dimensions of the intermittently coated portions 142 and theuncoated metal foil portions 144. For example, when the width (x) ofeach uncoated metal foil portion becomes greater, circumferentiallengths of the openings also become greater. In contrast, when the width(x) of each uncoated metal foil portion becomes smaller, circumferentiallengths of the openings also become smaller. Once the dimension of x isdefined, the dimension of the remaining portion (y) may be automaticallydefined.

During the laminating procedure in FIG. 12, the rollers 132 and 134 arepositioned adjacent to each other such that the openings 136 and 138 arealigned with each other as shown in FIG. 12. When the stacked layers(110, 120) are inserted between the rollers 132 and 134, the two layers(110, 120) are laminated into each other except for the portions thatpass through the openings 136 and 138, as the stacked layers (110, 120)are not pressed by the rollers 132, 134 in the openings 136 and 138. Thenon-pressed portions of the active free-standing film 110 may be peeledoff so that an intermittently coated dry electrode 140 is formed asshown in FIG. 13. The peeling procedure can be performed in the same waydescribed above with respect the previous embodiments.

Although each of the rollers 132 and 134 of FIG. 12 includes an opening,only one of the rollers 132 and 134 may have an opening. In thisembodiment, only one of the two layers (110, 120) is directly contactedby the rollers 132 and 134 in the opening area, during the laminatingroll procedure.

In another embodiment, each of the rollers 132 and 134 may include aplurality of openings (not shown). In this embodiment, each roller mayhave a dimension larger than the rollers 132 and 134 shown in FIG. 12.For example, two or more openings spaced apart from each other areformed in each of the rollers 132 and 134. These rollers may have thesame dimension and the same number of openings. Furthermore, theopenings of each roller may be circumferentially aligned with each otherduring the laminating roll procedure so that the same portions of theactive free-standing film 110 that form the x areas are not directlypressed by either of the rollers. The length of each of the openings maybe the same as the width (x) of each of the uncoated metal foil portions144. The distance between adjacent openings may be the same as the width(y) of each of the intermittently coated portions 142. In thisembodiment, the laminating procedure and the peeling procedure can bemore efficiently performed.

The above dry electrode making procedure can be applicable to asingle-side coated electrode, a double-side coated electrode, and anoffset coated electrode or asymmetric intermittent double-side coateddry laminate (double-side coated electrode with an intermittent patternon one side differing from the other side to be described with respectto FIGS. 17-20). In the double-side coated electrode, the intermittentpattern on one side can be symmetric to that on the other side.

FIGS. 14-16 illustrate a process of making an example dry electrodeaccording to another embodiment. In FIG. 14, an electrochemically activefree-standing film 150 and a metal foil 162 uncoated with an adhesiveare shown. The active free-standing film 150 may have the same dimensionas that of the active free-standing film 110 shown in FIG. 11. Theactive free-standing film 150 is placed over and aligned with theuncoated metal foil 162 before a laminator roll procedure in FIG. 15 isperformed.

Referring to FIG. 15, the active free-standing film 150 and the uncoatedmetal foil 162 are inserted into and laminated by a laminator rollassembly 170. The laminator roll assembly 170 includes a pair of rollers175 and 177. The rollers 175 and 177 may have substantially the samediameter. The rollers 175 and 177 may be formed of the same material ordifferent materials having the same level of hardness so that asubstantially uniform pressure is applied to the stacked layers (150,162) by both of the rollers 175 and 177.

The relative position (e.g., vertical position) of the rollers 175 and177 may be controlled such that a gap therebetween is periodicallyclosed or opened while the rollers 175 and 177 are being rotated. InFIG. 15, reference numerals 172 and 176 represent a closed gap, andreference numeral 174 represents an open gap. In one embodiment, theintermittent periodicity of an intermittently coated dry electrode 180shown in FIG. 16 can be governed by the duration of applied pressure tothe two layers 150 and 162 to produce a dimension x and a dimension y.In this embodiment, the dimension y, where the free-standing film 150 isattached to the metal foil 162, is produced when the rollers 175 and 177are closed (see 172 and 176 in FIG. 15). The length (y) or the width ofeach of intermittently coated portions 184 shown in FIG. 16 may beproportional to the duration of the rollers 175 and 177 being closed(172, 176). For example, the longer the duration of the rollers 175 and177 being closed, the larger the length y is, and vice versa.Furthermore, the dimension x, where the free-standing film 150 is notattached to (but merely placed over) the metal foil 162, is producedwhen the rollers 175 and 177 are opened (see 174 in FIG. 15). The length(x) between adjacent intermittently coated portions 184 may beproportional to the duration of the rollers 175 and 177 being opened(174). For example, the longer the duration of the rollers 175 and 177being opened (174), the larger the length x is, and vice versa. In oneembodiment, both of the rollers 175 and 177 are moved to open or closethe gaps therebetween. In another embodiment, only one of the rollers175 and 177 is moved to open or close the gaps therebetween.

When the gaps of the rollers 175 and 177 are closed (172, 176), thestacked layers (150 and 162) are pressed by the rollers 175 and 177 andthus laminated into each other. When the gaps of the rollers 175 and 177are opened (174), the stacked layers (150 and 162) are not pressed bythe rollers 175 and 177 and thus not laminated into each other (i.e.,merely placed over each other). The non-pressed portions of the activefree-standing film 150 are removed so that the intermittently coated dryelectrode 180 is formed as shown in FIG. 16. The removal procedure maybe performed in the same way described above with respect to theprevious embodiments. This way, the laminating procedure and the removalprocedure can be more efficiently performed.

The above dry electrode making procedure can be applicable to asingle-side coated electrode, a double-side coated electrode, and anoffset coated electrode or asymmetric intermittent double-side coateddry laminate (double-side coated electrode with an intermittent patternon one side differing from the other side to be described with respectto FIGS. 17-20).

FIGS. 17 and 18 illustrate a process of making an asymmetricintermittent double-side coated dry laminate 300 with the use of alaminator roll assembly 320 according to one embodiment. FIG. 17illustrates a laminator roll assembly 320 that produces the asymmetricintermittent double-side coated dry laminate 300 shown in FIG. 18according to an embodiment. FIG. 18 illustrates a cross-sectional viewof the asymmetric intermittent double-side coated dry laminate 300produced by the laminator roll assembly 320 shown in FIG. 17 accordingto an embodiment. As briefly described above with respect to FIGS. 14-16and as shown in FIG. 18, the asymmetric intermittent double-side coateddry laminate 300 (or offset coated dry electrode) is a double-sidedelectrode with an intermittent pattern on one side that differs from theother side.

Referring to FIG. 17, the laminator roll assembly 320 includes upper andlower laminator rollers 307 and 309. The roll assembly 320 receives afirst film roll 304, a second film roll 306 and a roll of an adhesivemetal foil 305. The first film roll 304 indicates a roll of anelectrochemically active free-standing film for a first intermittent drylaminate 301 shown in FIG. 18. The second film roll 306 indicates a rollof an electrochemically active free-standing film for a secondintermittent dry laminate 302 shown in FIG. 18. The adhesive metal foilroll 305 indicates a roll of an asymmetric intermittently coatedadhesive metal foil 303 shown in FIG. 18. The adhesive metal foil roll305 is interposed between the first and second film rolls 304 and 306when being inserted into the roll assembly 320. The first film roll 304,the metal foil roll 305 and the second film roll 306 may besimultaneously unwound as the films and the metal layer are insertedbetween and pressed by the upper and lower rollers 307 and 309.Similarly to the process shown in FIG. 15, the upper roller 307 iscontrolled to periodically press the first film roll 304 against theadhesive metal foil 305 to produce the first intermittent dry laminate301. For example, the first film roll 304 is pressed for a duration ofthe length “a” and not pressed for a duration of the length “b” shown inFIG. 18. Furthermore, the lower roller 309 is controlled to periodicallypress the first second film roll 306 against the adhesive metal foil 305to produce the second intermittent dry laminate 302. For example, thesecond film roll 306 is pressed for a duration of the length “c” and notpressed for a period of the length “d” shown in FIG. 18. The non-pressedareas may be removed from the laminated layer 308 in the same mannerdescribed above to produce the asymmetric intermittent double-sidecoated dry laminate 300 shown in FIG. 18. The removed portions may atleast partially vertically overlap each other. The film portions of thefirst intermittent dry laminate 301 may at least partially verticallyoverlap the film portions of the second intermittent dry laminate 302 asshown in FIG. 18.

Referring to FIG. 18, the first intermittent dry laminate 301 and thesecond intermittent dry laminate 302 are asymmetric to each other. Forexample, the length a of each of the laminated portions of the firstintermittent dry laminate 301 is different from the length c of each ofthe laminated portions of the second intermittent dry laminate 302.Furthermore, the length b of the exposed portion of the upper surface ofthe metal foil 303 is also different from the length d of the exposedportion of the lower surface of the metal foil 303. In some embodiments,the length b is less than the distance d as shown in FIG. 18. In otherembodiments, the length b is greater than the length d (not shown).Furthermore, in some embodiments, the length c is less than the length aas shown in FIG. 18. In other embodiments, the length c is greater thanthe length a (not shown).

Although FIGS. 17 and 18 show a process of making an asymmetricintermittent double-side coated dry laminate, a symmetric intermittentdouble-side coated dry laminate can also be made in the same way exceptthat the pressing interval or duration would be the same for the upperand lower laminator rollers 307 and 309. Furthermore, FIGS. 17 and 18show merely an example process of making an asymmetric intermittentdouble-side coated dry laminate, other roller assembly configurationsand/or other arrangements of film rolls and metal foil roll may also bepossible.

FIGS. 19 and 20 illustrate a process of making an asymmetricintermittent double-side coated dry laminate 310 with the use of alaminator roll assembly 340 according to another embodiment. FIG. 19illustrates the laminator roll assembly 340 that produces the asymmetricintermittent double-side coated dry laminate 310 shown in FIG. 20according to another embodiment. FIG. 20 illustrates a cross-sectionalview of the asymmetric intermittent double-side coated dry laminate 310produced by the laminator roll assembly 340 shown in FIG. 19 accordingto another embodiment. Referring to FIG. 19, the laminator roll assembly340 includes a first laminator roll assembly 350 and a second laminatorroll assembly 360. The first laminator roll assembly 350 includes afirst pair of laminator rollers 317 and 321, and the second laminatorroll assembly 360 includes a second pair of laminator rollers 323 and318. The roller 317 has an opening 352 with a width or circumferentiallength (b). The roller 318 has an opening 354 with a width orcircumferential length (d) which is different from the circumferentiallength (b).

The first roll assembly 350 receives a first film roll 314 and anuncoated metal foil roll 315. The first film roll 314 indicates a rollof an electrochemically active free-standing film for a firstintermittent dry laminate 311 shown in FIG. 20. The second roll assembly360 receives the first film roll 314, the uncoated metal foil roll 315and a second film roll 316. The second film roll 316 indicates a roll ofan electrochemically active free-standing film for a second intermittentdry laminate 312 shown in FIG. 20. The uncoated metal foil roll 315indicates a roll of an asymmetric intermittently coated adhesive metalfoil 313 shown in FIG. 20. The uncoated metal foil roll 315 isinterposed between the first and second film rolls 314 and 316 whenbeing inserted into the second roll assembly 360. In other embodiments,the second film roll 316 and the uncoated metal foil roll 315 may beinserted into the first roll assembly 350 while the first film roll 314(along with the second film roll 316 and the uncoated metal foil roll315) is inserted into the second roll assembly 360. In theseembodiments, the roller 321 would have an opening with a circumferentiallength d and the roller 323 would have an opening with a circumferentiallength b. The first film roll 314 and the metal foil roll 315 may beunwounded before the second film roll 316 is unwound.

Similarly to the process shown in FIG. 17, when the first film roll 314and the uncoated metal foil roll 315 are inserted into the rollers 317and 321 to produce a first laminated layer 330 when exiting the firstroll assembly 350, and subsequently the first laminated layer 330 andthe second film roll 316 are inserted into the rollers 323 and 318 toproduce a second laminated layer 319 when exiting the second rollassembly 360. The three layers 314, 315 and 316 are laminated into eachother except for the portions of the layers 314 and 316 that passthrough the openings 352 and 354. The non-pressed portions may beremoved from the second laminated layer 319 so that the asymmetricintermittent double-side coated dry laminate 310 is formed as shown inFIG. 20.

Although FIGS. 19 and 20 show a process of making an asymmetricintermittent double-side coated dry laminate, a symmetric intermittentdouble-side coated dry laminate can be made in the same way except thatthe widths of the openings would be the same for the upper and lowerlaminator rollers 317 and 318. Again, FIGS. 19 and 20 show merely anexample process of making an asymmetric intermittent double-side coateddry laminate, other roller assembly configurations and/or otherarrangements of film rolls and metal foil roll may also be possible.

FIG. 21 illustrates an intermittently coated dry electrode 198 to beconnected to an electrode tab according to an embodiment. Theintermittently coated dry electrode 198 includes laminated portions 192and 194 where an electrochemically active free-standing film islaminated onto a metal foil. The intermittently coated dry electrode 198further includes an uncoated metal foil portion 196 described above. Theuncoated metal foil portion 196 is used for connecting the dry electrode198 to an electrode tab (see FIG. 21) or other electrical component forconnection with an external device (not shown). Although FIG. 21 shows asingle uncoated metal foil portion 196, the electrode tab or otherelectrical component can be attached to one or more of a plurality ofuncoated metal foil portions, for example, shown in FIGS. 10, 13 and 16.

FIG. 22 illustrates an energy storage device 200 according to anembodiment. The energy storage device 200 can be a battery, a capacitoror a hybrid type that combines the battery and the capacitor. Thebattery can include a liquid electrolyte battery or a polymerelectrolyte battery or solid state battery. The polymer electrolyte mayinclude a solid polymer electrolyte and plasticized gel polymerelectrolyte. The liquid electrolyte battery may include a lithium ionbattery. The polymer electrolyte battery may include a lithium polymerbattery. The battery may have a cylindrical shape, a prismatic shape ora pouch shape.

The energy storage device 200 includes an electrode assembly 210. Theelectrode assembly 210 includes a first electrode 220, a secondelectrode 240, and a separator 230 positioned between the first andsecond electrodes 220 and 240. The separator 230 can be configured toelectrically insulate the first and second electrodes 220 and 240 whilepermitting ionic communication between the two electrodes 220 and 240.

The first electrode 220 can be an anode (a “negative electrode”) and thesecond electrode 240 can be a cathode (a “positive electrode”). Each ofthe anode and cathode electrodes 220 and 240 can be an intermittentlycoated dry electrode manufactured by one of the above describedprocedures of FIGS. 5-19. The first and second electrodes 220 and 240respectively include non-coated metal foil portions 222 and 242 whichare connected to respective electrode tabs 224 and 244 or otherelectrical components (not shown).

An energy storage device as provided herein can be of any suitableconfiguration, for example planar, spirally wound, button shaped, orpouch. An energy storage device as provided herein can be a component ofa system, for example, a power generation system, an uninterruptiblepower source systems (UPS), a photo voltaic power generation system, anenergy recovery system for use in, for example, industrial machineryand/or transportation. An energy storage device as provided herein maybe used to power various electronic device and/or motor vehicles,including hybrid electric vehicles (HEV), plug-in hybrid electricvehicles (PHEV), and/or electric vehicles (EV).

FIG. 23 illustrates a flowchart 2300 for a method of manufacturing a dryelectrode for an energy storage device according to an embodiment.Although the process flow diagram 2300 is described herein withreference to a particular order, in various embodiments, states hereinmay be performed in a different order, or omitted, and additional statesmay be added. This may apply to the flowchart 2400 shown in FIG. 24.

In state 2310, a metal layer is provided. For example, the metal layercan include a metal foil (58, 90, 120, 162) respectively shown in FIGS.5, 9, 11 and 14. In state 2320, an electrochemically activefree-standing film formed of a dry active material is provided. Forexample, the electrochemically active free-standing film can be anelectrochemically active dry film (56, 80, 110, 150) respectively shownin FIGS. 5, 8, 11 and 14. In state 2330, the electrochemically activefree-standing film and the metal layer are combined to form a combinedlayer. For example, the metal layer may be coated with an adhesive, theelectrochemically active free-standing film may be placed over the metallayer and heat and/or pressure can be applied to the film and metallayer to combine the two elements as described with respect to FIGS. 6and 9. As another example, the electrochemically active free-standingfilm may be placed over the metal layer, inserted between an opposingset of rollers and pressed by the rollers as described with respect toFIGS. 12 and 15.

In state 2340, a portion of the electrochemically active free-standingfilm is removed from the combined layer. For example, as described withrespect to FIGS. 7, 10, 13 and 16, portions of the electrochemicallyactive free-standing film in which an adhesive is not attached or whichare not pressed by the rollers can be removed from the metal layerportion of the combined layer via peeling or slitting. In state 2350,the electrochemically active free-standing film is intermittently formedon the metal layer in a longitudinal direction of the metal layer, forexample, as shown in FIGS. 7, 10, 13 and 16. As discussed above, theelectrochemically active free-standing film can be formed on only onesurface or opposing surfaces of the metal layer.

FIG. 24 illustrates a flowchart 2400 for a method of manufacturing a dryelectrode for an energy storage device according to another embodiment.In state 2410, a metal layer is provided. For example, the metal layercan include a roll of a metal foil (305, 315) shown in FIGS. 17 and 19.In state 2420, a first electrochemically active free-standing filmformed of a dry active material is provided. For example, the firstelectrochemically active free-standing film can include a roll of afirst film (304, 314) shown in FIGS. 17 and 19.

In state 2430, a second electrochemically active free-standing filmformed of a dry active material is provided. For example, the secondelectrochemically active free-standing film can include a roll of asecond film roll (306, 316) shown in FIGS. 17 and 19. In state 2440, thefirst and second electrochemically active free-standing films arecombined with the metal layer to form a combined layer such that themetal layer is interposed between the first and second electrochemicallyactive free-standing films. For example, the rolls of the first andsecond electrochemically active free-standing films with the metal layerinterposed therebetween are pressed by an opposing set of rollers (e.g.,one pair of rollers or two pairs of rollers) as described with respectto FIGS. 17 and 19.

In state 2450, a first portion of the first electrochemically activefree-standing film and a second portion of the first electrochemicallyactive free-standing film are removed from the combined layer asdescribed with respect to FIGS. 18 and 20. In state 2460, intermittentelectrochemically active free-standing films are formed on opposingsurfaces of the metal layer, for example, as shown in FIGS. 18 and 20.

As used herein, the terms “battery” and “capacitor” are to be giventheir ordinary and customary meanings to a person of ordinary skill inthe art. The terms “battery” and “capacitor” are nonexclusive of eachother. A capacitor or battery can refer to a single electrochemical cellthat may be operated alone, or operated as a component of a multi-cellsystem.

Features, materials, characteristics, or groups described in conjunctionwith a particular aspect, embodiment, or example are to be understood tobe applicable to any other aspect, embodiment or example described inthis section or elsewhere in this specification unless incompatibletherewith. All of the features disclosed in this specification(including any accompanying claims, abstract and drawings), and/or allof the steps of any method or process so disclosed, may be combined inany combination, except combinations where at least some of suchfeatures and/or steps are mutually exclusive. The protection is notrestricted to the details of any foregoing embodiments. The protectionextends to any novel one, or any novel combination, of the featuresdisclosed in this specification (including any accompanying claims,abstract and drawings), or to any novel one, or any novel combination,of the steps of any method or process so disclosed.

Furthermore, certain features that are described in this disclosure inthe context of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresthat are described in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations, one or more features from a claimedcombination can, in some cases, be excised from the combination, and thecombination may be claimed as a subcombination or variation of asubcombination.

Moreover, while operations may be depicted in the drawings or describedin the specification in a particular order, such operations need not beperformed in the particular order shown or in sequential order, or thatall operations be performed, to achieve desirable results. Otheroperations that are not depicted or described can be incorporated in theexample methods and processes. For example, one or more additionaloperations can be performed before, after, simultaneously, or betweenany of the described operations. Further, the operations may berearranged or reordered in other implementations. Those skilled in theart will appreciate that in some embodiments, the actual steps taken inthe processes illustrated and/or disclosed may differ from those shownin the figures. Depending on the embodiment, certain of the stepsdescribed above may be removed, others may be added. Furthermore, thefeatures and attributes of the specific embodiments disclosed above maybe combined in different ways to form additional embodiments, all ofwhich fall within the scope of the present disclosure. Also, theseparation of various system components in the implementations describedabove should not be understood as requiring such separation in allimplementations, and it should be understood that the describedcomponents and systems can generally be integrated together in a singleproduct or packaged into multiple products. For example, any of thecomponents for an energy storage system described herein can be providedseparately, or integrated together (e.g., packaged together, or attachedtogether) to form an energy storage system.

For purposes of this disclosure, certain aspects, advantages, and novelfeatures are described herein. Not necessarily all such advantages maybe achieved in accordance with any particular embodiment. Thus, forexample, those skilled in the art will recognize that the disclosure maybe embodied or carried out in a manner that achieves one advantage or agroup of advantages as taught herein without necessarily achieving otheradvantages as may be taught or suggested herein.

Conditional language, such as “can,” “could,” “might,” or “may,” unlessspecifically stated otherwise, or otherwise understood within thecontext as used, is generally intended to convey that certainembodiments include, while other embodiments do not include, certainfeatures, elements, and/or steps. Thus, such conditional language is notgenerally intended to imply that features, elements, and/or steps are inany way required for one or more embodiments or that one or moreembodiments necessarily include logic for deciding, with or without userinput or prompting, whether these features, elements, and/or steps areincluded or are to be performed in any particular embodiment.

Conjunctive language such as the phrase “at least one of X, Y, and Z,”unless specifically stated otherwise, is otherwise understood with thecontext as used in general to convey that an item, term, etc. may beeither X, Y, or Z. Thus, such conjunctive language is not generallyintended to imply that certain embodiments require the presence of atleast one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,”“about,” “generally,” and “substantially” as used herein represent avalue, amount, or characteristic close to the stated value, amount, orcharacteristic that still performs a desired function or achieves adesired result.

The scope of the present disclosure is not intended to be limited by thespecific disclosures of embodiments in this section or elsewhere in thisspecification, and may be defined by claims as presented in this sectionor elsewhere in this specification or as presented in the future. Thelanguage of the claims is to be interpreted broadly based on thelanguage employed in the claims and not limited to the examplesdescribed in the present specification or during the prosecution of theapplication, which examples are to be construed as non-exclusive.

While certain embodiments have been described, these embodiments havebeen presented by way of example only, and are not intended to limit thescope of the disclosure. Indeed, the novel methods and systems describedherein may be embodied in a variety of other forms. Furthermore, variousomissions, substitutions and changes in the systems and methodsdescribed herein may be made without departing from the spirit of thedisclosure. The accompanying claims and their equivalents are intendedto cover such forms or modifications as would fall within the scope andspirit of the disclosure. Accordingly, the scope of the presentinventions is defined only by reference to the appended claims.

What is claimed is:
 1. A method of manufacturing a dry electrode for anenergy storage device, comprising: providing a metal layer; providing anelectrochemically active free-standing film formed of a dry activematerial; combining the electrochemically active free-standing film andthe metal layer to form a combined layer; and removing a portion of theelectrochemically active free-standing film from the combined layer sothat the electrochemically active free-standing film is intermittentlyformed on the metal layer in a longitudinal direction of the metallayer.
 2. The method of claim 1, wherein the portion of theelectrochemically active free-standing film is removed to expose aportion of the metal layer disposed directly therebelow.
 3. The methodof claim 1, wherein the portion of the electrochemically activefree-standing film to be removed extends in a direction crossing thelongitudinal direction.
 4. The method of claim 1, wherein the metallayer comprises at least one coated portion coated with an adhesive andat least one uncoated portion not coated with an adhesive so that themetal layer is intermittently coated with the adhesive, and wherein theadhesive is disposed on a surface of the metal layer facing theelectrochemically active free-standing film so as to be adhered to theelectrochemically active free-standing film.
 5. The method of claim 4,wherein the intermittently coated metal layer is formed via gravure rollcoating or slot die coating.
 6. The method of claim 1, wherein thecombining comprises laminating the electrochemically activefree-standing film onto the metal layer.
 7. The method of claim 6,wherein the laminating comprises applying heat and/or pressure to atleast one of the electrochemically active free-standing film and themetal layer.
 8. The method of claim 4, wherein the portion of theelectrochemically active free-standing film to be removed verticallyoverlaps the uncoated portion of the metal layer.
 9. The method of claim4, wherein the adhesive comprises a conductive adhesive layer, andwherein a coating weight for the conductive adhesive layer is about 1gram per square meter per side to about 5 grams per square meter perside with a dry coating density of about 0.2 grams per square centimeterper side to about 1.1 grams per square centimeter per side.
 10. Themethod of claim 1, wherein the removing comprises peeling the portion ofthe electrochemically active free-standing film with an air knife and/orvacuum.
 11. The method of claim 1, wherein the metal layer is entirelyuncoated with an adhesive.
 12. The method of claim 11, wherein thecombining comprises intermittently pressing the electrochemically activefree-standing film and the metal layer with respect to each other with alaminator roll assembly.
 13. The method of claim 12, wherein thelaminator roll assembly comprises a pair of rollers at least one ofwhich includes an opening having a length.
 14. The method of claim 13,wherein the length of each opening is the same as a width of the portionof the electrochemically active free-standing film to be removed, andwherein the width is measured in the longitudinal direction.
 15. Themethod of claim 13, wherein the combining comprises aligning the atleast one opening of the rollers with the portion of theelectrochemically active free-standing film to be removed such that theportion of the electrochemically active free-standing film is notpressed by the rollers during rotation of the rollers.
 16. The method ofclaim 12, wherein the laminator roll assembly comprises a pair ofrollers adjacent to each other, and wherein the combining comprisesmoving at least one of the rollers with respect to each other such thata gap between the two rollers is periodically closed and opened duringrotation of the rollers.
 17. The method of claim 16, wherein a durationof the gap being opened is controlled to be proportional to a width ofthe portion of the electrochemically active free-standing film to beremoved, and wherein the width is measured in the longitudinaldirection.
 18. The method of claim 1, wherein the electrochemicallyactive free-standing film comprises sulfur.
 19. The method of claim 1,wherein the electrochemically active free-standing film is formed ononly one surface of the metal layer.
 20. The method of claim 1, whereinthe electrochemically active free-standing film comprises first andsecond electrochemically active free-standing films respectively formedon opposing surfaces of the metal layer.
 21. The method of claim 20,wherein intermittent patterns of the first and second electrochemicallyactive free-standing films are symmetric with respect to each other onthe opposing surfaces of the metal layer.
 22. The method of claim 20,wherein intermittent patterns of the first and second electrochemicallyactive free-standing films are asymmetric with respect to each other onthe opposing surfaces of the metal layer.
 23. A method of manufacturinga dry electrode for an energy storage device, comprising: providing ametal layer having first and second surfaces opposing each other;providing a first electrochemically active free-standing film formed ofa dry active material; providing a second electrochemically activefree-standing film formed of a dry active material; combining the firstand second electrochemically active free-standing films with the metallayer to form a combined layer such that the metal layer is interposedbetween the first and second electrochemically active free-standingfilms; and removing a first portion of the first electrochemicallyactive free-standing film and a second portion of the secondelectrochemically active free-standing film from the combined layer sothat the first and second electrochemically active free-standing filmsare intermittently formed respectively on the first and second surfacesof the metal layer in a longitudinal direction of the metal layer. 24.The method of claim 23, wherein the first and second portions of thefirst and second electrochemically active free-standing films have thesame length.
 25. The method of claim 23, wherein the first and secondportions of the first and second electrochemically active free-standingfilms have different lengths.
 26. The method of claim 23, wherein thefirst portion of the first electrochemically active free-standing filmcomprises a plurality of first film portions having the same length,wherein the second portion of the second electrochemically activefree-standing film comprises a plurality of second film portions havingthe same length and respectively facing the plurality of first filmportions, wherein each of the plurality of first film portions has afirst length, and wherein each of the plurality of second film portionshas a second length different from the first length.
 27. The method ofclaim 26, wherein each of the plurality of first film portions at leastpartially vertically overlaps a corresponding one of the plurality ofsecond film portions.
 28. The method of claim 23, wherein the combiningis performed with a laminator roll assembly comprising first and secondrollers adjacent to each other, and wherein the combining comprises:inserting the first and second electrochemically active free-standingfilms, and the metal layer between the first and second rollers suchthat the first roller faces the first electrochemically activefree-standing film, and the second roller faces the secondelectrochemically active free-standing film; moving the first and secondrollers with respect to each other such that a gap between the firstroller and the first electrochemically active free-standing film isperiodically closed and opened with a first duration, and a gap betweenthe second roller and the second electrochemically active free-standingfilm is periodically closed and opened with a second duration, whereinthe first and second durations are different from each other; andlaminating the first and second electrochemically active free-standingfilms onto the metal layer with the first and second rollers to producethe combined layer.
 29. The method of claim 28, wherein each of thefirst and second electrochemically active free-standing films is formedof a roll of an electrochemically active free-standing film, wherein themetal layer is formed of a roll of a metal foil, and wherein the rollsof first and second electrochemically active free-standing films and theroll of the metal foil are simultaneously unwounded when the activefree-standing films and the metal layer are inserted between and pressedby the first and second rollers.
 30. The method of claim 23, wherein thecombining is performed with a laminator roll assembly comprising a setof first and second rollers and a set of third and fourth rollers spacedapart from each other, and wherein the combining comprises: insertingthe first electrochemically active free-standing film and the metallayer into the set of first and second rollers, wherein the first rollerhas a first opening and the second roller has no opening; laminating thefirst electrochemically active free-standing film onto the metal layerwith the set of first and second rollers to produce a laminated layer;inserting the laminated layer and the second electrochemically activefree-standing film between the set of third and fourth rollers such thatthe third roller faces the first electrochemically active free-standingfilm of the laminated layer, and the fourth roller faces the secondelectrochemically active free-standing film, wherein the fourth rollerhas a second opening and the third roller has no opening, and whereinthe first and second openings have different circumferential lengths andface opposite sides of the metal layer; and laminating the secondelectrochemically active free-standing film onto the metal layer of thelaminated layer with the set of third and fourth rollers to produce thecombined layer.
 31. The method of claim 28, wherein each of the firstand second electrochemically active free-standing films is formed of aroll of an electrochemically active free-standing film, wherein themetal layer is formed of a roll of a metal foil, and wherein the roll ofthe first electrochemically active free-standing film and the roll ofthe metal foil are unwounded before the roll of the secondelectrochemically active free-standing film is unwounded.
 32. The methodof claim 23, wherein the second electrochemically active free-standingfilm comprises sulfur.